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Intelligent upgrade and quality control strategy of wheel hub factory production line
2024-10-12
The research in this paper focuses on the production line of wheel hub factories and explores intelligent upgrade paths and quality control methods.
I. Introduction
1.1 Research Background
The production line of wheel hub factories is crucial in automobile manufacturing. Intelligence and quality control have become key development directions. With the booming development of the automobile industry, wheel hubs, as important components of automobiles, directly affect the driving safety and comfort of cars. The efficient operation and quality control of the production line of wheel hub factories are of utmost importance for automobile manufacturers. In today's era, the rapid development of intelligent technology has brought new opportunities and challenges to the production line of wheel hub factories. For example, the MES intelligent manufacturing control system developed by Qingdao Lead Intelligent Automation Equipment Co., Ltd. covers the entire product manufacturing cycle. Starting from multiple aspects such as people, machines, materials, methods, and measurements, it systematically improves the on-site management level of enterprise intelligent manufacturing production. The addition of industrial robots enables the production line to only require one or two staff members for loading and unloading work. The rest of the work can be completed by robots and production units. The peak rhythm can reach 6 minutes per piece. At the same time, quality control is also a key link in the production line of wheel hub factories. From supplier relationship management to quality control in the production process and then to after-sales service, every link is related to the quality of the final product. For example, wheel hub companies manage and control the production process in strict accordance with quality standards and environmental requirements, establish a perfect quality management system, strengthen the professionalism and accuracy of detection and inspection, and improve the quality and competitiveness of products. In the production of wheel hub wire drawing machines, brand accessories are selected for installation and matching, and quality is strictly controlled. The continuous improvement of research and development performance has improved the product quality standard. In short, intelligence and quality control have become the key directions for the development of wheel hub factory production lines. Only by continuously improving the intelligent level and strengthening quality control can we remain invincible in the fierce market competition.
1.2 Research Purpose
This research aims to explore intelligent upgrade paths and efficient quality control methods for wheel hub factory production lines to meet the continuous development needs of the automobile industry. With the progress of science and technology, intelligence has become the development trend of the manufacturing industry. In the production line of wheel hub factories, intelligent upgrades can improve production efficiency, reduce costs, and enhance product quality. For example, through independent research and development of intelligent systems, Lead Automation has accelerated production efficiency. Its automated wheel hub production line only requires one or two staff members for loading and unloading work. The rest of the work is completed by robots and production units. The peak rhythm can reach 6 minutes per piece. In addition, the automated solution for industrial robot wheel hub grippers in intelligent automobile production enables robots to accurately identify and grasp wheel hubs through advanced sensor technology and image recognition systems, greatly improving production efficiency and reducing errors. At the same time, efficient quality control methods are crucial for the production line of wheel hub factories. Starting from supplier relationship management, the evaluation and selection of suppliers should be strengthened, considering factors such as strength, response speed, quality management, time control, and cost control. In the production process, the production process should be managed and controlled in strict accordance with quality standards and environmental requirements, and a perfect quality management system should be established. For example, in the production and manufacturing quality management of wheel hub companies, by strengthening the professionalism and accuracy of detection and inspection, the quality and competitiveness of products are improved. In the production of wheel hub wire drawing machines, brand accessories are selected for installation and matching, and quality is strictly controlled. The continuous improvement of research and development performance has improved the product quality standard. Through the exploration of intelligent upgrade paths and efficient quality control methods for wheel hub factory production lines, useful references can be provided for wheel hub manufacturing enterprises to help enterprises achieve sustainable development in the fierce market competition.
II. Intelligent Equipment for Wheel Hub Factory Production Lines
2.1 Advanced Numerical Control Processing Equipment
2.1.1 Application of CNC Lathes in Wheel Hub Processing
In common wheel hub processing, CNC lathes play a crucial role. CNC lathes are basic equipment for wheel hub processing and can achieve rough and fine processing of wheel hubs. Through programming control, CNC lathes can accurately complete the processing of dimensions such as the inner and outer diameters, width, and roundness of wheel hubs. For example, in the processing process, CNC lathes can quickly and accurately cut the wheel hub blank according to the preset program to make it initially formed. At the same time, CNC lathes can also perform fine processing to ensure that the dimensional accuracy of the wheel hub reaches a high standard. According to statistics, using CNC lathes for wheel hub processing can control the dimensional error within a very small range, usually within ±0.05 millimeters, greatly improving the quality and performance of the wheel hub.
2.1.2 CNC Grinding Machines Improve Wheel Hub Precision
CNC grinding machines play a key role in the fine processing of wheel hubs. It is mainly used for the fine processing of wheel hubs, such as improving the precision of the inner and outer diameters, end faces, chamfers and other parts. CNC grinding machines have the characteristics of high precision and high efficiency and can meet the production needs of high-end wheel hubs. In actual production, CNC grinding machines can reduce the surface roughness of wheel hubs to a very small value through precise grinding processes, making the surface more smooth and improving the appearance quality of wheel hubs. At the same time, CNC grinding machines can also precisely adjust the size of wheel hubs to ensure that the precision of wheel hubs meets the design requirements. For example, some high-end automobile brands have extremely high precision requirements for wheel hubs. CNC grinding machines can control the roundness error of wheel hubs within 0.02 millimeters, providing a strong guarantee for the driving safety and comfort of automobiles.
2.2 Intelligent Production Line Equipment
2.2.1 Automation Conveying and Smart Factory Cases
Taking Jieli Wheel Hub as an example, the automated conveying equipment in its smart factory plays a huge role. At Chongqing Jieli Wheel Hub Manufacturing Co., Ltd. in Dianjiang Industrial Park, the first domestic intelligent flexible automated production line for motorcycle aluminum alloy wheel hubs has been officially completed and put into production. This production line 引用 AI video control application technology, greatly improving the product classification efficiency. At the same time, combined with the industrial Internet platform, automated conveying equipment can effectively control production logistics, realize the rapid conversion production of more than 100 products on the same production line at the same time, and greatly improve production efficiency. Automated conveying equipment enables wheel hub blanks to circulate quickly and accurately between various processes. From five processes such as drilling valve holes and disc brake processing, it can become a semi-finished product before spraying in just 15 minutes. Compared with traditional production lines, the production efficiency has increased by nearly seven times. In addition, automated conveying equipment also reduces labor costs and human errors, ensuring the stability of product quality.
2.2.2 5G Intelligent Cloud Factory Dispatch Center
Taking Dicastal Wheel Hub as an example, the 5G intelligent cloud factory dispatch center has significant advantages. At Sanmenxia Dicastal Wheel Hub Manufacturing Co., Ltd., a series of parameters such as the cooling state, temperature, and pressure value of the equipment in the 5G intelligent cloud factory dispatch center are dynamically updated on the display screen. All process production instructions are issued from here to achieve full real-time monitoring. With the help of China Mobile's 5G network, Dicastal Wheel Hub has realized the upgrade of the "intelligent factory". In the production process, through the 5G network, enterprises have realized the system data transmission between the PLCs of the logical control operation electronic system and between the PLC and the in-plant system. While ensuring data security and real-time performance, it reduces the wiring cost in the workshop and quickly realizes the production capacity matching of the production line. 5G enables flexible production and increases processing efficiency by 10%. At the same time, 5G+X-ray defect detection makes wheel hub quality inspection more intelligent. Through high-definition real-time images, workers can quickly capture defects, perform alarms, quality inspections and sorting. A single machine can replace 6 to 8 workers and prevent the troubles caused by false defects. 5G+AR intelligent 点检 makes experts always "by your side". Equipment maintenance personnel can quickly collect the high-definition machine content seen through the worn AR glasses. After experts in the distance view and annotate it, the workers in the workshop can quickly and clearly find the problems existing in the machine parts. The 5G+equipment operation online monitoring system realizes real-time monitoring and intelligent diagnosis, which can help managers comprehensively and accurately evaluate the working conditions of important equipment and provide data support for maintenance personnel for equipment maintenance, effectively reducing unplanned downtime of enterprise equipment, improving equipment service life, and realizing the health management of the entire life cycle of production equipment, bringing significant economic benefits to enterprises.
III. Technological Process of Wheel Hub Factory Production Line
3.1 Pretreatment Process
3.1.1 Importance of Passivation Film Treatment
The passivation film treatment in the pretreatment process of automobile aluminum alloy wheel hubs plays a crucial role. By forming a passivation film, it can effectively protect the wheel hub from being contaminated by mud, sewage, etc. during driving. In daily driving, long-term contact of ground stains with aluminum alloy wheel hubs is prone to cause corrosion. The passivation film is like a strong protective armor, greatly reducing the possibility of corrosion and thereby achieving the purpose of prolonging the life of automobile aluminum alloy wheel hubs. For example, in practical applications, wheel hubs treated with passivation films can maintain a good state under various complex road conditions, reducing wheel hub damage caused by corrosion and providing a reliable guarantee for the safe driving of cars.
3.1.2 Advantages of Spray Pass-Through Equipment
Spray pass-through equipment has extensive application advantages in the pretreatment process of automobile aluminum alloy wheel hubs. First of all, by using spray pass-through equipment for pretreatment of automobile aluminum wheels, a comprehensive passivation film can be formed on the aluminum alloy wheel hubs. Compared with other pretreatment equipment, spray pass-through equipment can spray the treatment liquid on the wheel hub surface more evenly, making the formation of the passivation film more complete and stable. According to statistics, wheel hubs treated with spray pass-through equipment can achieve a passivation film coverage rate of more than 95%, greatly improving the corrosion resistance of the wheel hubs. Secondly, spray pass-through equipment has high processing efficiency. It can complete the pretreatment work of a large number of wheel hubs in a short time and improve production efficiency. For example, in some large-scale wheel hub factories, spray pass-through equipment can process hundreds of wheel hubs per hour, meeting the needs of large-scale production. In addition, spray pass-through equipment is simple to operate and easy to maintain, reducing the operating cost of enterprises. It has a high degree of automation and can realize continuous operation, reducing manual intervention and improving the stability and consistency of production.
3.2 Grinding Process
3.2.1 Selection of Different Grinding Equipment
Due to the irregular shape and grooves of aluminum alloy wheel hubs, when grinding automobile wheel hubs, appropriate grinding equipment should be selected according to the actual situation of the wheel hubs. Plane grinders are suitable for grinding the plane of wheel hubs. The working principle is to grind the plane of the wheel hub through a high-speed rotating grinding disc, which can quickly remove flaws and uneven parts on the plane and make the wheel hub plane smooth and flat. For example, when dealing with large flat areas of wheel hubs, plane grinders can efficiently complete the task and generally reduce the roughness of the plane to a very small value, improving the appearance quality of the wheel hub. For positions with large grooves, angle grinders can be selected for grinding treatment. Angle grinders have the characteristics of high flexibility and can operate in narrow spaces. For difficult-to-reach parts such as large grooves on wheel hubs, they can exert their unique advantages. It grinds the grooves through a rotating grinding wheel and can effectively remove defects such as burrs and rust in the grooves. When dealing with smaller grooves, pneumatic grinding heads can be selected as processing equipment. Pneumatic grinding heads are small in size, easy to operate, and can precisely grind small grooves. The high-speed rotating grinding head can penetrate into the small grooves and remove fine defects. According to statistics, reasonable selection of different grinding equipment for wheel hub grinding can increase grinding efficiency by more than 30% and ensure that the grinding quality of all parts of the wheel hub meets high standard requirements.
3.2.2 Grinding Safety and Quality Control
Safety measures are crucial during the grinding process. Since waste materials generated during grinding are easy to cause injuries to workers, operators must wear corresponding protective clothing such as safety glasses, protective gloves, and protective masks to prevent splashes generated during grinding from harming the body. In addition, enterprises need to set up a special grinding platform to ensure that the grinding work is carried out in a safe environment. The grinding platform should have a good ventilation system to timely remove the dust generated during grinding and reduce the harm to operators. At the same time, quality inspection also has important significance during the grinding process. Before grinding, a comprehensive inspection of the automobile wheel hub is required to determine the specific grinding location and degree, and a corresponding construction plan can be formulated before grinding. After the grinding is completed, the automobile aluminum wheel hub needs to be inspected a second time to ensure that the quality of the equipment after grinding is qualified, the appearance beauty is improved, and there are no grooves or protrusions. Through strict quality inspection, problems existing in the grinding process can be found in time to ensure that the quality of the wheel hub meets the production requirements. For example, after quality inspection, the surface flatness of the wheel hub can reach within ±0.02 millimeters, greatly improving the appearance quality and performance of the wheel hub.
3.3 Powder Spraying Process
3.3.1 Powder Spraying Thickness and Performance Improvement
The powder spraying thickness plays a crucial role in the corrosion resistance and aesthetics of the wheel hub. At present, when powder spraying is performed, the powder spraying thickness is usually selected as 100 microns. Such a thickness can effectively improve the aesthetics of the wheel hub, making the wheel hub surface more smooth and uniform, and the color more full. At the same time, it can also greatly enhance the impact resistance and corrosion resistance of the wheel hub. During driving, wheel hubs will inevitably be impacted by road stones and eroded by various corrosive substances. Appropriate powder spraying thickness can provide a strong protective layer for the wheel hub and reduce the damage caused by these factors to the wheel hub. According to statistics, when the powder spraying thickness is 100 microns, the corrosion resistance of the wheel hub can be increased by more than 30%, and the impact resistance can also be significantly enhanced, so that the wheel hub can effectively meet the current automobile driving requirements, improve the service life of the automobile wheel hub, and achieve the basic guarantee for the life safety of the driver. After powder spraying on the aluminum alloy wheel hub, the powder can cover the defects on the wheel hub surface and lay a solid foundation for the subsequent painting process.
3.3.2 Advantages of Powder Spraying Production Line
Automotive parts production enterprises have realized the production line production of powder spraying process, and this production method has many advantages such as high efficiency and safety. The specific production line includes thermal energy system, curing furnace, chain conveyor, production waste recycling equipment, powder spraying workshop and powder spraying gun. First of all, production line production greatly reduces the input of human resources during powder spraying operations. In the traditional production method, powder spraying work often requires a large amount of manual operation, which is not only inefficient but also has high labor intensity. Production line production can realize automated operation. Only a small number of staff are required for monitoring and maintenance, greatly improving production efficiency. For example, an automated powder spraying production line can process dozens or even hundreds of wheel hubs per hour, which is several times more efficient than the traditional method. Secondly, production line production improves the safety of powder spraying treatment. During the powder spraying process, a large amount of dust and harmful gases will be generated. If not handled properly, it will cause serious harm to the health of workers. The production waste recycling equipment and good ventilation system in production line production can effectively collect and treat these harmful substances, reducing pollution to the environment and the human body. At the same time, automated operation also reduces the contact between workers and dangerous substances and reduces the occurrence probability of safety accidents. In addition, production line production can also ensure the stability and consistency of powder spraying quality. Through precise control systems, it can ensure that the powder spraying thickness and quality of each wheel hub meet standard requirements and improve the overall quality level of products.
3.4 Painting Process
3.4.1 Paint Types and Wheel Hub Quality
Colored paint and clear paint play a crucial role in the wheel hub painting process and have a significant impact on the corrosion resistance and aesthetics of the wheel hub. Colored paint gives the wheel hub rich colors and meets consumers' demands for personalized appearances. At the same time, colored paint can also enhance the corrosion resistance of the wheel hub to a certain extent. Different colors of colored paint may have different chemical properties and corrosion resistance. For example, some dark-colored colored paints may contain more anti-rust ingredients and can better resist the erosion of corrosive substances. According to statistics, wheel hubs treated with high-quality colored paint can increase their corrosion resistance by more than 20%.
Clear paint mainly plays the role of protecting colored paint and enhancing the gloss of wheel hubs. Clear paint forms a transparent protective film on the surface of the wheel hub, which can prevent colored paint from being damaged by external factors such as ultraviolet rays, rain, and dust. Clear paint can also make the surface of wheel hubs more smooth and improve the aesthetics of wheel hubs. In actual production, the quality of clear paint directly affects the final appearance effect of wheel hubs. Generally speaking, high-quality clear paint has good wear resistance, weather resistance and corrosion resistance, and can maintain good aesthetics and protective performance of wheel hubs for a long time. For example, some wheel hubs treated with high-quality clear paint can still maintain good gloss and corrosion resistance after long-term use.
In short, the reasonable combination of colored paint and clear paint can effectively improve the corrosion resistance and aesthetics of wheel hubs and add luster to the overall appearance and performance of automobiles.
3.4.2 Comparison of Manual and Automatic Painting Methods
Manual painting and automatic painting have their own advantages and disadvantages, and their application situations are also different.
The advantage of manual painting is its high flexibility. Operators can perform fine painting operations according to the specific shape and requirements of the wheel hub to ensure that each part is evenly sprayed. For some wheel hubs with complex shapes and special requirements, manual painting can better meet production needs. In addition, manual painting is relatively cost-effective for small batch production or special customization of wheel hubs. However, manual painting also has some disadvantages. First of all, it has high technical requirements for operators. Operators must have sufficient painting experience and skills to ensure that the surface paint of the aluminum alloy wheel hub after painting treatment is uniform and the appearance is flat. Otherwise, quality problems such as uneven painting, sagging